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2009 YFM25RY
Yamaha 2009 YFM25RY Manuals
Manuals and User Guides for Yamaha 2009 YFM25RY. We have
1
Yamaha 2009 YFM25RY manual available for free PDF download: Service Manual
Yamaha 2009 YFM25RY Service Manual (293 pages)
Brand:
Yamaha
| Category:
Offroad Vehicle
| Size: 13.05 MB
Table of Contents
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Important Information
11
Preparation for Removal and Disassembly
11
Replacement Parts
11
Gaskets, Oil Seals and O-Rings
12
Lock Washers/Plates and Cotter Pins
12
Bearings and Oil Seals
12
Circlips
12
Checking the Connections
13
Special Tools
14
Specifications
19
General Specifications
20
Engine Specifications
23
Chassis Specifications
29
Electrical Specifications
31
Tightening Torques
33
General Tightening Torque Specifications
33
Engine Tightening Torques
34
Chassis Tightening Torques
36
Lubrication Points and Lubricant Types
38
Engine
38
Lubrication System Chart and Diagrams
40
Engine Oil Lubrication Chart
40
Lubrication Diagrams
42
Cable Routing
48
Periodic Checks and Adjustments
63
Periodic Maintenance
66
Introduction
66
Periodic Maintenance Chart for the Emission Control System
66
General Maintenance and Lubrication Chart
67
Engine
69
Adjusting the Valve Clearance
69
Adjusting the Engine Idling Speed
70
Adjusting the Throttle Cable Free Play
71
Adjusting the Speed Limiter
72
Checking the Spark Plug
72
Checking the Ignition Timing
73
Measuring the Compression Pressure
73
Checking the Engine Oil Level
74
Changing the Engine Oil
75
Adjusting the Clutch Cable Free Play
77
Cleaning the Air Filter Element
77
Checking the Carburetor Joint and Intake Manifold
78
Checking the Fuel Line
79
Checking the Cylinder Head Breather Hose
79
Checking the Exhaust System
79
Cleaning the Spark Arrester
79
Chassis
81
Adjusting the Front Disc Brake
81
Adjusting the Brake Pedal
81
Checking the Brake Fluid Level
82
Checking the Front Brake Pads
83
Checking the Rear Brake Pads
83
Checking the Front Brake Hoses
83
Checking the Rear Brake Hose
83
Adjusting the Parking Brake
84
Adjusting the Rear Brake Light Switch
84
Bleeding the Hydraulic Brake System
85
Adjusting the Shift Pedal
86
Adjusting the Drive Chain Slack
86
Lubricating the Drive Chain
87
Checking the Steering System
87
Adjusting the Toe-In
88
Checking the Front Shock Absorber Assemblies
89
ADJUSTING the FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3D)
89
ADJUSTING the FRONT SHOCK ABSORBER ASSEMBLIES (for 4D3H, 4D3M)
90
Checking the Rear Shock Absorber Assembly
92
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for 4D3D)
92
ADJUSTING the REAR SHOCK ABSORBER ASSEMBLY (for 4D3H, 4D3M)
93
Checking the Tires
94
Checking the Wheels
96
Checking and Lubricating the Cables
96
Lubricating the Levers
96
Lubricating the Pedal
96
Electrical System
97
Checking and Charging the Battery
97
Checking the Fuses
97
Replacing the Headlight Bulbs
97
Adjusting the Headlight Beams
97
Chassis
99
General Chassis
103
Front Wheel
106
Removing the Front Wheels
106
Checking the Front Wheels
106
Checking the Front Wheel Hubs
106
Checking the Front Brake Discs
107
Installing the Front Wheel Hub Bearings
107
Installing the Front Brake Discs
107
Installing the Front Wheel Hubs
107
Adjusting the Front Wheel Static Balance
108
Installing the Front Wheels
109
Rear Wheel
110
Removing the Rear Wheels
111
Checking the Rear Wheels
111
Checking the Rear Wheel Hubs
111
Installing the Rear Wheel Hubs
111
Adjusting the Rear Wheel Static Balance
111
Installing the Rear Wheels
111
Rear Axle and Rear Axle Hub
112
Removing the Rear Axle
114
Checking the Rear Axle
114
Checking the Rear Axle Hub
114
Checking the Rear Wheel Sprocket
115
Checking the Sprocket Bracket
115
Installing the Rear Wheel Sprocket
115
Installing the Rear Axle
115
Front Brake
116
Introduction
121
Checking the Front Brake Discs
121
Replacing the Front Brake Pads
122
Removing the Front Brake Calipers
122
Disassembling the Front Brake Caliper
123
Checking the Front Brake Caliper
123
Assembling the Front Brake Caliper
124
Installing the Front Brake Caliper
124
Removing the Front Brake Master Cylinder
125
Checking the Front Brake Master Cylinder
125
Assembling the Front Brake Master Cylinder
126
Installing the Front Brake Master Cylinder
126
Rear Brake
128
Introduction
133
Checking the Rear Brake Disc
133
Replacing the Rear Brake Pads
133
Removing the Rear Brake Caliper
134
Disassembling the Rear Brake Caliper
135
Checking the Rear Brake Caliper
135
Assembling the Rear Brake Caliper
135
Installing the Rear Brake Caliper
136
Removing the Rear Brake Master Cylinder
137
Checking the Rear Brake Master Cylinder
137
Assembling the Rear Brake Master Cylinder
138
Installing the Rear Brake Master Cylinder
138
Handlebar
140
Removing the Handlebars
141
Checking the Handlebar
141
Installing the Handlebar
141
Steering Stem
144
Checking the Steering Stem
145
Installing the Steering Stem
145
Installing the Lock Washer
145
Tie-Rods and Steering Knuckles
147
Removing the Steering Knuckles
147
Checking the Tie-Rods
147
Checking the Steering Knuckles
147
Installing the Tie-Rods
147
Front Arms and Front Shock Absorber Assemblies
148
Removing the Front Arms
149
Checking the Front Arms
149
Handling the Front Shock Absorber and Gas Cylinder
149
Disposing of a Front Shock Absorber and Gas Cylinder
149
Checking the Front Shock Absorber Assemblies
150
Checking the Front Arm Ball Joints
150
Installing the Front Arms and Front Shock Absorber Assemblies
150
Rear Shock Absorber Assembly
152
Handling the Rear Shock Absorber
153
Disposing of a Rear Shock Absorber
153
Removing the Rear Shock Absorber Assembly
153
Checking the Rear Shock Absorber Assembly
153
Installing the Rear Shock Absorber Assembly
154
Swingarm
155
Removing the Swingarm
156
Checking the Swingarm
156
Installing the Swingarm
157
Engine
163
Engine Removal
169
Installing the Engine
169
Installing the Muffler and Exhaust Pipe
169
Camshaft
171
Removing the Rocker Arms and Camshaft
172
Checking the Camshaft
172
Checking the Rocker Arms and Rocker Arm Shafts
173
Installing the Camshaft and Rocker Arms
174
Cylinder Head
175
Removing the Cylinder Head
177
Checking the Cylinder Head
177
Checking the Timing Chain Guides
178
Checking the Timing Chain Tensioner
178
Installing the Cylinder Head
179
Valves and Valve Springs
182
Removing the Valves
182
Checking the Valves and Valve Guides
182
Checking the Valve Seats
184
Checking the Valve Springs
186
Installing the Valves
187
Cylinder and Piston
190
Removing the Piston
190
Checking the Cylinder and Piston
190
Checking the Piston Rings
191
Checking the Piston Pin
192
Installing the Piston and Cylinder
192
Clutch
194
Removing the Clutch
197
Checking the Friction Plates
197
Checking the Clutch Plates
198
Checking the Clutch Springs
198
Checking the Clutch Housing
198
Checking the Clutch Boss
198
Checking the Pressure Plate
199
Checking the Clutch Push Rods
199
Checking the Primary Drive Gear
199
Installing the Clutch
199
Oil Pump
203
Removing the Oil Pump
205
Checking the Oil Pump
205
Assenbling the Balancer Weight Gear
206
Installing the Oil Pump
206
Installing the Balancer Weight Gear
206
Checking the Shift Shaft
208
Checking the Stopper Lever
208
Installing the Shift Shaft
208
Pickup Coil Rotor and Starter Clutch
211
Removing the Pickupcoil Rotor
211
Checking the Starter Clutch
211
Installing the Pickup Coil Rotor
212
Electric Starter
214
Checking the Starter Motor
216
Assembling the Starter Motor
217
Crankcase
218
Disassembling the Crankcase
220
Checking the Crankcase
220
Assembling the Crankcase
220
Crankshaft Assembly
222
Removing the Crankshaft Assembly
223
Removing the Plunger Seal
223
Checking the Crankshaft and Connecting Rod
223
Checking the Timing Chain
224
Checking the Crankshaft Sprocket
224
Checking the Timing Chain Guide
224
Installing the Plunger Seal
224
Installing the Crankshaft Assembly
224
Transmission
226
Removing the Transmission
228
Checking the Shift Forks
228
Checking the Shift Drum Assembly
228
Checking the Transmission
229
Installing the Shift Forks and Shift Drum Assembly
230
Fuel System
231
Fuel Tank
232
Checking the Fuel Cock
233
Checking the Fuel Cock Operation
233
Removing the Fuel Tank
233
Carburetor
234
Checking the Carburetor
237
Assembling the Carburetor
238
Installing the Carburetor
239
Electrical System
241
Ignition System
242
Circuit Diagram
242
Troubleshooting
244
Electric Starting System
246
Circuit Diagram
246
Starting Circuit Cut-Off System Operation
248
Troubleshooting
250
Charging System
252
Circuit Diagram
252
Troubleshooting
254
Lighting System
256
Circuit Diagram
256
Troubleshooting
258
Signaling System
260
Circuit Diagram
260
Troubleshooting
262
Carburetor Heating System
264
Circuit Diagram
264
Troubleshooting
266
Electrical Components
268
Checking the Switches
270
Checking the Bulbs and Bulb Sockets
273
Checking the Fuses
274
Checking and Charging the Battery
274
Checking the Relays
278
Checking the Diode
278
Checking the Spark Plug Cap
279
Checking the Ignition Coil
279
Checking the Pickup Coil
280
Checking the Starter Motor Operation
281
Checking the Stator Coil
281
Checking the Rectifier/Regulator
282
Checking the Thermo Switch
282
Checking the Carburetor Warmer
283
Troubleshooting
285
General Information
285
General Information
286
Starting Failures
286
Troubleshooting
286
Faulty Clutch
287
Faulty Gear Shifting
287
Incorrect Engine Idling Speed
287
Jumps out of Gear
287
Poor Medium-And-High-Speed Performance
287
Shift Pedal Does Not Move
287
Faulty Lighting or Signaling System
288
Overheating
288
Poor Braking Performance
288
Unstable Handling
288
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